The functionality of milk powder and its relationship to chocolate mass processing, in particular the effect of milk powder manufacturing and composition on the physical properties of chocolate masses

Summary The functionality of twelve different milk powders that are used for chocolate mass processing was investigated. In two types of spray‐dried and one type of roller‐dried powder, the milk fat and milk fat fractions were integrated. Depending on the production process, the amount of free fat available in the milk powders varied greatly. A good correlation was found between the free fat content of the milk powder and the viscosity of the chocolate mass when comparable particle sizes were used. This study reports on the development of spray‐dried milk powders, which when used in chocolate processing produced low viscosities, comparable with those obtained by using roller‐dried milk powder. Calorimetric analysis showed that the shape of the milk powder particles has no influence on the calorimetric qualities of chocolate masses. Only when milk fat was added in a free form, was a higher ‘mixing effect’ in the crystallization peak of cocoa butter and milk fat observed.     

Influence of milk proteins on the development of lactose-induced stickiness in dairy powders

The stickiness behaviour of a range of spray dried dairy powders differing in protein/lactose ratio was determined using a fluidised bed apparatus. Powders with higher protein/lactose ratios were less susceptible to sticking. Stickiness was related to both the glass transition temperature (T_g) and the temperature increment by which T_g must be exceeded before sticking occurred (T?T_g). T?T_g values of approximately 10, 22, 29, 45 and 90 °C were found for powders containing 15.5, 26.9, 39.5, 55.7 and 83.4% protein respectively. Composition had different effects on T_g and T?T_g. The rate at which water was sorbed and desorbed by powders increased with protein content. With increasing protein content, preferential sorption of water by non-amorphous constituents delayed the rate at which lactose underwent the requisite change from the ‘glassy’ to the ‘rubbery’ form in order that powder particles became sticky.     

Effects of selected properties of ultrafiltered spray-dried milk powders on some properties of chocolate

The effects of selected properties of spray-dried milk fat powders on chocolate were determined. Milk powders produced from control or ultrafiltered (UF) milks with various levels of fat were blended with skim milk powder to give a standard 26 g fat 100 g⁻¹ powder. Particle size of the chocolate mixes after refining decreased as the fat content and free-fat content of the powders increased. Despite this, increasing fat and free-fat contents of powders reduced the Casson viscosity of the subsequent molten chocolates. Casson viscosities using powders from control or UF milks were similar, but decreased as the particle size of powders increased and particle size after refining the chocolate mix decreased. Casson yield value and hardness decreased as fat content of powders increased. Casson yield value increased with vacuole volume of powders. It is possible to alter important properties of chocolates using milk powders of varying fat contents, free-fat contents and particle sizes.     

Thickening of molten white chocolates during storage

When white chocolates are kept molten in storage tanks, problems can arise due to uncontrolled thickening and solidifying of the chocolate mass. The thickening of molten white chocolate was simulated on a laboratory scale using a rotational rheometer under static conditions, interrupted by short shear periods to measure the increasing viscosity. Several chocolates having different dairy components and fat contents were investigated for their tendency to thicken. In addition, sorption isotherms for white chocolates were obtained using Dynamic Vapour Sorption at different temperatures. The sorption isotherms showed the presence of amorphous lactose in all the chocolates that were manufactured from milk powders. Moisture that is released during the crystallisation of amorphous lactose causes stickiness and agglomeration of the neighbouring particles and starts the thickening process. This process is highly temperature-dependent. On elevating the temperature the lactose crystallisation occurs at lower relative humidities. In order to reduce the tendency of white chocolate to thicken, a high free fat level should be maintained, based on a high total fat content and on the use of high free fat milk powders, preferably roller-dried whole milk powders or the combination of skimmed milk powder and anhydrous milk fat.     

Thickening of molten white chocolates during storage

When white chocolates are kept molten in storage tanks, problems can arise due to uncontrolled thickening and solidifying of the chocolate mass. The thickening of molten white chocolate was simulated on a laboratory scale using a rotational rheometer under static conditions, interrupted by short shear periods to measure the increasing viscosity. Several chocolates having different dairy components and fat contents were investigated for their tendency to thicken. In addition, sorption isotherms for white chocolates were obtained using dynamic vapour sorption at different temperatures. The sorption isotherms showed the presence of amorphous lactose in all the chocolates that were manufactured from milk powders. Moisture that is released during the crystallization of amorphous lactose causes stickiness and agglomeration of the neighbouring particles and starts the thickening process. This process is highly temperature-dependent. On elevating the temperature the lactose crystallization occurs at lower relative humidities. In order to reduce the tendency of white chocolate to thicken, a high free-fat level should be maintained, based on a high total fat content and on the use of high free-fat milk powders, preferably roller-dried whole milk powders or the combination of skimmed milk powder and anhydrous milk fat.     

A Process for Increasing the Free Fat Content of Spray-dried Whole Milk Powder

Exposing spray‐dried whole milk powder to high shear and elevated temperature in a twin‐screw continuous mixer increased the free fat content. The effects of operating conditions (powder feed rate, processor screw speed, and process temperature) on lactose crystallinity, particle size distribution, color, and moisture content of spray‐dried whole milk powder were investigated using response surface methodology. Exposure to elevated temperatures and high shear: (a) increased the free fat to more than 80%, (b) crystallized the lactose, (c) reduced the average volume‐based particle size, and (d) broadened the particle size distribution. The raw whole milk powder with creamy‐white color turned into an oily paste with bright‐yellow color. Processing enhanced the functional properties of spray‐dried whole milk powder for milk chocolate manufacture.     

Retention of Diacetyl in Milk during Spray-Drying and Storage

Spray-drying of milk in a Leaflash dryer was studied in relation to volatile aroma loss in drying and during storage of the powders. Diacetyl was used as the volatile model, and the contribution of the various milk constituents to retention was determined. Proteins retain more diacetyl than does lactose or fat. Conditions leading to a powder with more amorphous lactose result in higher diacetyl loss during drying. The rate of diacetyl loss during storage depended on relative humidity and on the T — T_g parameter and was strongly enhanced by crystallization of amorphous lactose.     

Effect of protein concentration on the surface composition,water sorption and glass transition temperature of spray-dried skim milk powders

The effects of dilution of protein content in skim milk (34–8.5% protein content), by lactose addition, on the surface composition, water sorption property and glass transition temperatures of spray-dried powders were investigated. The X-ray photoelectron spectroscopy (XPS) study of spray-dried powders showed preferential migration of proteins toward the surface of the milk particles whereas the lactose remained in the bulk. Sorption studies showed that the lower protein concentration in milk powders is linked to an increased water adsorption property and lowering of water activity (a_w) for lactose crystallization. Analysis of glass transition temperature (T_g) of the powders sorbed at different humidities showed no distinct change in T_g values, indicating the dominant effect of lactose on the glass transition temperature of all the powders.     

Analysis of particle-gun-derived dairy powder stickiness curves

The stickiness curves of a range of dairy powders were measured using a particle-gun rig. The stickiness curves for the powders were shown to run parallel but above the curve of the glass transition temperature (T_g) of amorphous lactose. By assuming that the amorphous lactose at the surface of the powder was in equilibrium with the exit conditions of the air from the particle gun, it was found that for any particular dairy powder sample, the amount of powder deposition measured on the particle-gun target disc collapsed into a single function of the temperature difference by which the amorphous lactose T_g at the surface was exceeded. The x-axis intercept of these plots was calculated and designated as (T−T_g)_crit, characterizing the conditions for initiation of stickiness of the powder. The sensitivity of each powder to stickiness problems when placed in conditions where the critical T−T_g value at the surface is exceeded was quantified with the slope of the plot. These results show that it is the amorphous lactose component that is probably the main cause of stickiness in dairy powders and demonstrates how the particle-gun rig can be used to characterize the stickiness behaviour of powders over a wide range of conditions with two parameters.     

Influence of milk components on properties and consumer acceptance of milk chocolate

The objective of the study was to assess the effects of various milk components on chocolate quality, defined by measurable properties and decisively by consumer liking.The choice of milk products considered different types, technologies and suppliers. Samples produced under standardised conditions were analysed for particle size, flow properties, colour and by a trained sensory panel. Consumer testing determined overall liking. Results revealed that milk ingredients influence consumer liking of milk chocolate through the quality driving parameters of particle size/sandiness, viscosity/melting mouthfeel and milk flavour. Chocolates made from milk products that contain high amounts of free fat - e.g. skim milk powder plus anhydrous milk fat - scored better than those using bound fat - e.g. whole milk powder. Milk fat status had more influence than differences between spray and roller-dried powders. High free fat cream powders were most suitable for cream chocolates. All milk components need to be free from off-notes that require sensory checks. Fillers like lactose could replace some sucrose, and whey protein concentrate can partially replace skim milk powder.     

Impact of amorphous and crystalline lactose on milk chocolate properties

Chocolate mass of low viscosity is preferred for most applications. Milk powder influences processing behaviour, flow properties and taste of milk chocolate. The project aimed to investigate influences of skim milk powders containing amorphous or crystalline lactose on flow properties after producing samples by roller milling and conching or alternatively by ball milling. For the first case, it was found that mass consistency before roller milling is strongly influenced by lactose type; producers must specify it and adapt initial mass fat content. Little impact on final products was found after processing milk powders at equilibrium moisture. If predried powders are used for reducing conching time, crystalline lactose leads to chocolate with slightly lower viscosity. At ball mill processing, crystalline lactose resulted in significantly lower viscosity, for example 15% at 40 s^?1; thus, for this process, it can be recommended to use special milk powders high in crystalline lactose content.     

In-situ lecithination of dairy powders in spray-drying for confectionery applications

Powders are essential ingredients of chocolate. In particular for milk chocolate milk and whey powders are important, together with sucrose, lactose and cocoa solids. During processing to maintain a good flow of the molten chocolate mass, particles with hydrophilic surfaces, such as dairy powders and sugars, are coated with a surface-active compound. Only lecithin and polyglycerol polyricinoleate (PGPR) (at a limited level) are allowed in chocolate, and as these are expensive as little as possible is added, whilst maintaining rheological properties. Conventionally, lecithin is added during conching, and through the intense kneading of the chocolate mass it is distributed throughout the mass. Usually about 0.5% is added, although the level depends upon the composition of the chocolate. Here we present a new approach to lecithination of spray-dried milk and lactose powders, which we call in-situ lecithination. It has been found that the surface of a spray-dried powder is dominated by any surface-active species, and in a competitive situation, the most rapidly adsorbing species dominates. This behaviour is utilised when lecithin is added to the spray-dryer feed, and through the competitive adsorption of surface-active agents during the drying process, it dominates the powder surface composition as measured by X-ray photoelectron spectroscopy (XPS). This is also seen in differences in sedimentation rate when the powders are mixed with cocoa butter to assess the rheological properties of the powder dispersions. The effect was large for lactose powders, but smaller for skim milk powder and whey powder.     

Influence of protein concentration on surface composition and physico-chemical properties of spray-dried milk protein concentrate powders

Surface composition, moisture sorption behaviour and glass–rubber transition temperature (T_gr) were determined for spray-dried milk protein concentrate (MPC) powders over a range of protein contents (35–86 g 100 g⁻¹). Surface characterisation of MPC powders indicated that fat and protein were preferentially located on the surface of the powder particles, whereas lactose was located predominantly in the bulk. Moisture sorption analysis at 25 °C showed that MPC35 exhibited lactose crystallisation, whereas powders with higher protein contents did not and continually absorbed moisture upon humidification up to 90% RH. The GAB equation, fitted to sorption isotherms of MPCs, gave increases in monolayer moisture value (m_m) with protein content. T_gr, measured with a rheometer, decreased significantly (P < 0.05) with increasing water content and increased with increasing protein content (P < 0.05). In conclusion, increasing protein concentration of MPCs resulted in altered surface composition and increased m_m value and T_gr values.     

Invited review: spray-dried dairy and dairy-like emulsions--compositional considerations

Milk constituents [caseins, whey proteins (WP), lactose, and anhydrous milk fat] are used widely in the manufacture of dehydrated dairy and dairy-like emulsions. When sodium caseinate- (NaCas) and WP-stabilized emulsions with an oil-to-protein ratio ranging from 0.25 to 5 are dehydrated, NaCas is a more effective encapsulant than WP because of its superior emulsifying properties and resistance to heat denaturation. Denaturation degree of WP during drying has been associated with increased powder surface fat and larger droplet size after reconstitution. Encapsulation of NaCas-stabilized emulsions improves in the presence of lactose; powder surface fat was reduced from 30 to <5% when lactose was added at a 1:1 ratio to NaCas in an emulsion containing 30% (wt/wt) oil. This has been related to the ability of lactose to form solid-like (or glassy) capsules during sudden dehydration. Encapsulation of WP-stabilized emulsions is not improved by addition of lactose, although there are conflicting reports in the literature. Storage stability of dehydrated dairy-like emulsions is strongly linked to lactose crystallization as release of encapsulated material occurs during storage at high relative humidities (e.g., 75%). The use of alternative carbohydrates as “matrix-forming” materials (such as maltodextrins or gum arabic) improves storage stability but compromises the emulsion droplet size after reconstitution. The composition of the powder surface has been recognized as a key parameter in dehydrated emulsion quality. It is the chemical composition of the powder surface that dictates the behavior of the bulk in terms of wettability, flowability, and stability. Analyses, using electron spectroscopy for chemical analysis of the surface of industrial milk powders and dehydrated emulsions that mimicked the composition of milk, showed that powder surface is covered mainly by fat, even when the fat content is very low (18 and 99% surface fat coverage for skim milk and whole milk powders, respectively). The functional properties of milk constituents during emulsion dehydration are far from being thoroughly understood; future research needs include a) the encapsulation properties of pure micellar casein; b) a deeper understanding of colloidal phenomena (such as changes in the oil-water and air-oil interfaces) that occur before, during, and after dehydration, which ultimately define emulsion stability after drying; and c) reconciliation of the current different views on powder surface composition.     

Stickiness curves of high fat dairy powders using the particle gun

High fat (>42%) dairy powders are inherently sticky due to their high levels of liquid surface fat. Incorrect operating conditions when spray drying these powders can rapidly lead to blockages. The particle gun was used to characterise the stickiness curves of high fat cream and cheese powders. Stickiness was shown to increase with increasing temperature to a maximum at 50 °C after which it decreased until no stickiness was observed above 68 °C. A dramatic increase in stickiness for the powders was found when the relative humidity of the air was increased past a certain critical point for each temperature. This was attributed to the lactose component of the powder exceeding its glass transition temperature by a critical amount. Best estimates of the (T−T_g)_crit. values for White Cheese Powder, Low Fat Cream Powder and High Fat Cream Powder were 28, 37 and 38 °C, respectively.     

Effects of milk powders in milk chocolate

The physical characteristics of milk powders used in chocolate can have significant impact on the processing conditions needed to make that chocolate and the physical and organoleptic properties of the finished product. Four milk powders with different particle characteristics (size, shape, density) and "free" milk fat levels (easily extracted with organic solvent) were evaluated for their effect on the processing conditions and characteristics of chocolates in which they were used. Many aspects of chocolate manufacture and storage (tempering conditions, melt rheology, hardness, bloom stability) were dependent on the level of free milk fat in the milk powder. However, particle characteristics of the milk powder also influenced the physical and sensory properties of the final products.     

CHARACTERIZATION OF RECONSTITUTED MILK POWDER BY ULTRASOUND SPECTROSCOPY

When instant milk powder (IMP) is reconstituted with water, the product should resemble fresh milk. However, undissolved particles were found at the surface and in the bulk of the product. A visual reconstitution test (RT) is made on IMP to determine the reconstituted quality of the product. This test is directly linked to the presence of the undissolved particles. The particles found at the surface are formed by clustered liquid‐fat aggregates, which rise to the top of the milk and may give an impression of spoiled milk. The particles found in the bulk are small particles in the solution mostly composed of a protein gel. Because the repeatability and precision of the RT are very poor, a quantitative analytical technique is desirable. In this study we investigated five different quality milk powders by an ultrasound spectroscopy technique. The ultrasonic velocity and attenuation parameters were measured with a frequency scanning pulse echo reflectometer. We found that the ultrasonic velocity cannot be correlated to RT because the predominant phenomenon that affects the ultrasonic velocity is the physical state of the different components of the milk matrix (liquid fat, crystalline fat and lactose crystals), and this physical state is not a significant factor in powder quality. However, the ultrasonic attenuation coefficient is well correlated with RT. This is because, between two different quality powders, the most important factor that causes variation in the attenuation is scattering, correlated to particle size and to volume fraction rather than by the composition or physical state of the matrix and the same particle size factor, and volume fraction factor characterizes the powder reconstitution's quality.     

Viscosity of Molten Milk Chocolate with Lactose from Spray-Dried Whole-Milk Powders

Dry whole-milk powders containing 0, 30, 50 and 70% nominal lactose prepared by spray-drying alone, or followed by post-drying crystallization, were incorporated into milk chocolate to give 0–50% substitution of lactose for sucrose. Increasing the concentration of amorphous lactose from spray-dried powders in the chocolates decreased viscosity, increased particle size of refined chocolate mass, and lowered the concentration of surface-active agents at which a minimum in Casson yield value was observed. Increasing the concentration of crystalline lactose from milk powders in the chocolates increased viscosity, decreased particle size, and increased the concentration of surface-active agents at which a minimum in Casson yield value was observed. Conditions which affect lactose crystallinity in milk powders, such as improper storage and handling prior to use in chocolate production, could be responsible for variations in chocolate viscosity noted sometimes by processors.     

Effect of Sucrose on Physical Properties of Spray‐Dried Whole Milk Powder

ABSTRACT: Spray‐dried whole milk powders were prepared from whole condensed milk with various sucrose concentrations (0%, 2.5%, 5%, 7.5%, and 10% w/w), and their glass transition temperature and some physical properties of importance in chocolate manufacture were evaluated. In milk powder samples, the glass transition temperature and free‐fat content decreased in a nonlinear manner with sucrose addition. Moreover, increasing sucrose concentration reduced the formation of dents on the particle surface. Addition of sucrose in whole condensed milk increased linearly the apparent particle density and in a nonlinear manner the particle size of spray‐dried milk powders. The particle size volume distribution of milk powders with the highest sucrose concentration differed from the log‐normal distribution of the other samples due to the formation of large agglomerates. Neither vacuole volume, nor the amorphous state of milk powders was affected by sucrose addition.     

Influence of particle size on the physicochemical properties and stickiness of dairy powders

The compositional and physicochemical properties of different whey permeate (WPP), demineralised whey (DWP) and skim milk powder (SMP) size fractions were investigated. Bulk composition of WPP and DWP was significantly (P < 0.05) influenced by powder particle size; smaller particles had higher protein and lower lactose contents. Microscopic observations showed that WPP and DWP contained both larger lactose crystals and smaller amorphous particles. Bulk composition of SMP did not vary with particle size. Surface composition of the smallest SMP fraction (<75 μm) showed significantly lower protein (−9%) and higher fat (+5%) coverage compared with non-fractionated powders. For all powders, smaller particles were more susceptible to sticking. Hygroscopicity of SMP was not affected by particle size; hygroscopicity of semi-crystalline powders was inversely related to particle size. This study provides insights into differences between size fractions of dairy powders, which can potentially impact the sticking/caking behaviour of fine particles during processing.